Lessons Learned, Fuel Cell Vehicle and Hydrogen Infrastructure
2015.04 Dr. Sae Hoon Kim Fuel Cell Group Eco-Technology Center Hyundai Motor Company Global Forecast
- Global energy consumption will increase 3 times from 2000 to 20501)
- In 2035, 90% of global energy consumption increment will occur in non-OECD countries2)
- In 2013, CO2 concentration level was more than 400ppm 1)Royal Dutch Shell / 2)International Energy Agency (IEA) Presentation
Global Energy and Environmental Issue
[ppm] @ Mauna Loa Observatory 400 Yearly average 375
350 Monthly average
325
300 1960 1970 1980 1990 2000 2010 Source : World Key Energy Statics (IEA, 2013) Source : Mauna Loa Observatory (EIA, 2013) EU CO2 Reduction
- Road transportation: 95 % CO2 reduction is required
▶ 2020 EU CO2 target: 95 gCO2/km, Expected 2025 CO2 target: 70 gCO2/km
EU CO2 Reduction
Source : EU Hydrogen and FCEV Coalition Global Forecast
- Many countries will focus on lower carbon energy resources
- Transportation sector consumes over 60% of total produced oil and makes 23% of GHG
Renewable Energy and Regulation
USA EU China 20% 20% Fuel Economy CAFE CO2 Regulation Regulation Avg. Regulation 14% 15% 56 130g/km 8.6 ℓ/100km 51 9.2% 34.2mpg 95 6 8% 9.8%↑ 24%↑ 49%↑ 27%↑
- Penalty : - Penalty : - Penalty : Not issuing $5.5 / 0.1mpg x €95 / 1 g/km x certificate ’13 ’20 ’13 ’20 ’13 ’20 Total Sales Vol. Total Sales Vol. (Not allowed to sale) USA EU China Future Energy Scenario: Hydrogen Society
- “Survival scenario”: hydrogen production with cheap coal The way to use of Hydrogen is
- Ideal scenario: hydrogen production by renewable energy (solar / wind) fuel cell technology
Flexibility of Hydrogen Future Scenario
▣ Fossil fuel reserves - Coal (113 yrs.), Natural gas (55 yrs.), Oil (53 yrs.)
Source : BP Statistical Review of World Energy 2014
▣ Future scenario Future Energy Scenario: Hydrogen Society
- Hydrogen can be stored in large scale
- Hydrogen storage is essential for realizing the Smart Grid
SOURCE: BMU “Leitstudie” 2010
[MW] LoadLoad curve Curve and and wind Wind power Power in inthe the Vattenfall German gridGrid (독일 동북부 지역) 35,00035.000 Potential charge and discharge periods 30,00030.000 1,000 GWh =1,400,000,000m3 (water) 25,00025.000 = 115*Goldisthal 0.6 GWh = 370,000,000m3 (Air) Compressed Air = 1,500*Hundorf 20,00020.000 (Huntorf) = 500,000m3 (Hydrogen) 8.48 GWh 15,00015.000 Total Pumped Hydro (Goldisthal)
10,00010.000
5,0005.000 Charge Discharge 0 23 1Jan 24 Jan 25 Jan 26 Jan 27 Jan 28 Jan 29 Jan 30 Jan 31 Jan 01 Feb 02 Feb 03 Feb
estimated wind power 2030 (4 x 2008) load 2008 History of Fuel Cells
1839 William Grove invents 1st fuel cell
1958 GE engineers invent PEMFC (W. T. Grubb & L. Niedrach)
1965
Fuel cells in Apollo (12kW AFC) 1966 GM develops FCEV
1980s US Navy uses fuel cells 1990s in submarines Ballard starts to supply PEMFC to Daimler and Ford
2013 Hyundai begins world’s 1st “series production” of FCEV Fuel Cell and FCEV
Fuel Cell
▣ Chemical Reaction
GDL: Gas Diffusion Layer MEA: Membrane Electrode Assembly
Fuel Cell Electric Vehicle
Improvement of PEMFC Performance
- 2008: 100 times, 2014: 140 times higher, compared to world’s first PEMFC
- Performance of PEMFC is expected to be 200 times higher in 2020
Performance of PEMFC 1.2
1 1.2 [Unit cell] [Multi cell] 1959 Willard. T. Grubb 0.8 1 1965 David L. Douglas and Elton J. Cairns 2008 Industry Average 1959 Willard. T. Grubb
0.6 0.8 2014 Industry Average 1965 David L. Douglas and Elton J. Cairns
0.4 2008 Industry Average 0.6 2014 Industry Average 0.2
0.4 Dead cell in
Cell Voltage [V] Cell Voltage
0 view of 0 500 0.21000 1500 today’s 2000 technology
0 0 500 1000 1500 2000 W. T. Grubb (1959) D. L. Douglas & E.J. Cairns Current density [mA/cm2] (1965) History of FCEVs
1966 General Motors ‘Electrovan’ 1993 The first fuel cell car FC: 32 kW, 115 kph, 240 km Energy Partners Consulier The world’s first PEMFC car FC: 15 kW, 95 kph, 95 km 1997 Daimler Chrysler ‘NECAR 3’ First methanol reforming FCEV 2000 FC: 50 kW, 120 kph, 400 km Hyundai ‘Santa Fe FCEV’ Hyundai's 1st generation FCEV FC: 75 kW, 124 kph, 160 km 2006 General Motors ‘Equinox FCEV’ 2007 FC: 93 kW, 160 kph, 320 km Honda ‘FCX Clarity’ Lease from 2008 ($600/month for 3 years ) FC: 100 kW, 160 kph, 570 km 2009 Mercedes-Benz ‘F-Cell’ FC: 90 kW, 170 kph, 385 km 2013 Hyundai ‘Tucson ix Fuel Cell’ 2015 Series production FC: 100kW, 160 kph, 595 km Toyota FCV-R FC:100kW, 160 kph, 700 km Hyundai’s FCEVs
Current : 10,000psi (700bar) tank -25ºC (-13ºF) cold start
- Power density ↑ - Optimized operating conditions - Large scale production - Power density ↑
Technology Level Technology - Series production
<100kW Stack>
<80kW stack> - Carbon bipolar plates <100kW stack> <~100kW stack> - Ambient pressure operation - Metal bipolar plates - Metal bipolar plates Past Present Future ix 35 (Tucson ix) FCEV: Specifications
EU US
Fuel Cell 100kW Power
Battery 24kW
Max. Power 136ps 134hp
30.6kgf-m / 221lb.-ft. / Max. Torque 1,000rpm 1,000rpm
Motor System AC Induction / 100 kW Fuel Cell System 5.64kg 12.4lb. H Container 2 (@700bar) (@10,000psi) 0.95kgH / 50MPGe Fuel Economy 2 100km (Combined) 594km 265miles Driving Range (NEDC Mode) (Fuel Economy Label) Acceleration 12.5s (0 → 100km) Motor High Voltage Hydrogen Max. Speed 160kph 100mph Battery Container ※ NEDC : New European Driving Cycle Fuel Economy Label : 70% of EPA mode test results Fuel Cell Bus: Specifications
Fuel Cell Power 200 kW
Super capacitor 100 kW
Max. Power 402hp
Motor System PM Motor / 300 kW
40 kg (@350 bar) H2 Container 86 lb. (@5,000 psi)
4.49 kgH /100km (@60 kph) Fuel Economy 2 10.75 kgH2/100km (@Local Mode)
440 km Driving Range (Local Mode)
Acceleration 8.5 s (0 → 50km)
Max. Speed 103 kph / 64 mph Vehicle Performance Test - Durability
- Durability of FCEV on real road reached over 224,000 km (140,000miles) by applying advanced components, system, and control technologies. - Excellent correlation between laboratory data of system and vehicle data !!
Performance Degradation
Vehicle Performance Test – Hot Weather
High temperature test at Death Valley Long distance test drive: 2,900km (1,800 miles)
▪ Outside temperature: 40~47ºC (104~ 117ºF) ▪ 1,300km (800miles) at Mojave, 1,600km (1,000miles) at Death valley
Gradability test at Towne Pass (`14.8) High altitude test in Denver, CO. (`14.8)
▪ Elevation change: 0 m → 1,500 m (4,920ft) ▪ Verified performance of vehicle at 1.6~4.3 km (5,250~14,100ft) altitude
Vehicle Performance Test – Cold Weather
Cold test in environmental chamber Cold test in Mt. Taebak
▪ Chamber temperature : -20ºC (-4ºF) ▪ Outside temperature : -19ºC (-2.2ºF)
Cold test in Sweden High attitude test in Bolzano: 2.8km (9000ft)
▪ Outside temperature reached -41.5ºC (-42.7ºF) ▪ Outside temperature : -8ºC (17.6ºF) Hydrogen Safety
- Fire, drop, gun-fire and cycle tests of hydrogen tank + Vehicle fire test
Safety Tests
Hydrogen tank tests Vehicle fire test
Before Fire Test After Fire Test 1. Fire 2. Drop
Before TPRD TPRD Operation Start End 3. Gun Fire 4. Cycle test Operation (13min) TPRD: Temperature Pressure Relief Device Crashworthiness Test
- Rear (80kph (50mph) / 70% offset) and front (56kph (35mph) / 40% offset) collisions
▶ No hydrogen leakage / satisfy electrical safety req’t (ECE regulation)
Collision Test
Hydrogen tank safety Electrical safety
ECE R94.02 Rear 56 kph, 40% offset
500 Front 50 (V) 400400 3000 30 3.48sec., 60VDC 200200
100100 Stack Voltage Stack 00
Stack Voltage [V] StackVoltage 00 1010 2020 3030 4040 5050 6060 TimeTime (sec)[sec] FCEV Demonstration Projects
Participation of Region Project Hyundai ▣ 1st US DOE Fleet Program - California and Michigan / 2004-2009 / 7 parties USA ▣ 2nd US DOE Fleet Program - California / 2013-2015 / 6 parties ▣ H2moves Scandinavia - Norway and Denmark / 2010- 2013 (36 months) / 8 parties ▣ Europe HyTEC - London and Copenhagen / 2011- 2014 (40 months) / 15 parties ▣ HyFIVE - UK, Denmark, Southern Germany / 2014-2017 (40 months) / 15 parties ▣ JHFC Phase 1 - Tokyo and metropolitan area / 2002-2005 / 22 parties Japan ▣ JHFC Phase 2 - Tokyo and metropolitan area, Nagoya and Osaka / 2006-2010 / 25 parties
▣ 1st Korean Domestic Fleet Program - Seoul / 2006-2010 / 5 parties Korea ▣ 2nd Korean Domestic Fleet Program - Seoul and Ulsan / 2009-2013 / 6 parties Activities for Technology Verification
DOE Demonstration Project Hope on Wheels (HOW)
▪ 32 Fuel Cell SUVs in California and Michigan (’04 - ’09) ▪ Charity event for children cancer patients in US (‘11.10)
H2moves Project in Europe Zero Drives : Oslo to Monaco
▪ 4 Tucson Fuel Cells in Oslo and Copenhagen (’11 – ‘12) ▪ 2,300km (1,400miles) driving without mobile H2 station (‘12.04)
[Launching Event] Activities for Technology Verification
YEOSU EXPO 2012 Portable Fuel Cell Generator
▣ Hyundai sponsored and supported the event ▣ Provide electricity to home appliances from - Drive and Ride of 30 FCEVs a ix35 (Tucson ix) Fuel Cell
(25 SUVs and 5 Buses) - One Stationary PEMFC Power Plant
[Drive & Ride]
[Camping] [Emergency power supply] [Elec. Power in Korea Pavillion] US DOE Project
- Emphasized on the FCEV durability and its driving range
Durability
Durability Improvement Key Performance Korean Demonstration Project
- Emphasized on reliability of vehicles and components
▶ Technical issues and malfunctions drastically decreased
Reliability
Total Malfunctions Malfunctioned Components
Main Components
Stack MEA and Catalyst
BOP Blower, Pump, Sensor
Motor Motor controller, Inverter
Control Stack voltage monitor
H2 storage Hydrogen tank valves and sensors Real Road Experience
- US DOE fleet: Frontal crash accident in California → normal operation of airbag, no injury
- Korean domestic fleet: Frontal crash accident
Accidents on Real Road
US DOE fleet Korean domestic fleet Lesson Learned : Cost
- Low manufacturing volume, monopoly of certain components such as membranes
- Need to overcome “Valley of Death” through mass production
Stack Cost Estimation
Lesson Learned: Durability
- Long term target: 15 years (7,500 hrs.) and 300,000km
- Main causes to degradation: Carbon corrosion / ionomer contamination / membrane degradation
Vehicle Durability Technology Strategy
▣ Catalyst - Durable carbon support : Graphitizing carbon support : Increasing surface stability of carbon support
▣ Membrane - Additive for chemical durability : Incorporating radical scavengers - Enhancement of membrane robustness : Including reinforcement layer Lesson Learned : Public Awareness
- General public still feel as that a hydrogen tank is a hydrogen bomb!! - FCEVs are not well promoted to the public yet. Most people do not know what an FCEV is! - Expand educational and promotional programs for FCEVs
Public Education
Wrong Awareness Promotional Program Memorable Milestones
1999 California Fuel Cell Partnership 2004 DOE Fleet
2010 EU Hydrogen FCEV Coalition FCEV Commercialization 2011 by 2015 H2Mobility World’s 1st Joint Study for hydrogen and FCEV 2013 The Strategic Energy Plan of Japan 100 HRSs by 2015 2014 Hydrogen is a secondary energy CEC Announcement 100 HRSs by 2023 2015 Tucson FCV: Ward’s 10 Best Engines What To Do Next